Honeywell 7800 series Operating instructions

Brand: Honeywell

Model: 7800 series

Type: Operating instructions

This manual is also suitable for

RM7888A

INSTALLATION INSTRUCTIONS

32-00214-01

SIL3

Capable

RM7888A

7800 SERIES Relay Module

APPLICATION

The Honeywell RM7888A Relay Module is a

microprocessor based, integrated burner control for

industrial process semiautomatically fired gas, oil, coal, or

combination fuels for single and multiple burner

industrial applications. The RM7888A requires a Relay

Module, Subbase and Amplifier for operation. Options

include Keyboard Display Module, DATA CONTROLBUS

MODULE™, Modbus™ Module, and Remote Display

Mounting.

The RM7888 intended use is in conjunction with a master

system control. The master system control determines the

purge timing and confirms air supply and air flow. The

RM7888A is programmed to provide a level of safety,

functional capability and features beyond the capability of

conventional controls. The basic functions of the RM7888

include automatic burner startup sequencing, five user

selectable operating (run) sequences, four line voltage

sequence control inputs (commonly controlled with a

Programmable Logic Controller [PLC)], flame supervision,

system status indication, system or self-diagnostics and

troubleshooting.

This document covers the following 7800 Series Relay

Modules:

RM7888A1019

RM7888A1027

RM7888A2019

RM7888A2027

Contents

Specifications ............................................................................... 2

Ordering Information ................................................................ 2

Principal Technical Features .................................................. 9

Saftey Provisons .......................................................................... 10

Installation ..................................................................................... 11

Wiring ............................................................................................... 13

Assembly ......................................................................................... 15

Operation ........................................................................................ 19

Static Checkout ............................................................................ 30

Checkout ......................................................................................... 32

Troubleshooting ........................................................................... 38

RM7888A 7800 SERIES RELAY MODULE

32-00214—01 2

FEATURES

• Safety features:

— Closed loop logic test.

—Dynamic input check.

— Dynamic safety relay test.

— Dynamic self-check logic.

— Expanded safe-start check.

— Internal hardware status monitoring.

— Tamper resistant timing and logic.

• Access for external electrical voltage checks.

• Application flexibility.

• Communication interface capability using Modbus.

• First-out annunciation and system diagnostics are

provided by the optional Keyboard Display Module.

• Five sequence information LEDs.

• Interchangeable plug-in flame amplifiers.

• Local or remote annunciation of RM7888A operation

and fault information.

• Dependable, long-term operation provided by

microcomputer technology.

• Nonvolatile memory for retaining history files and

sequencing status after loss of power.

• Remote reset capability (optional).

• Burner controller data:

— Sequence status.

— Sequence time.

—Hold status.

—Lockout/alarm status.

— Flame signal strength.

— Expanded annunciator status.

— Total hours of operation.

— Total cycles of operation.

— Fault history of six most recent faults:

• Cycles of operation at the time of the fault.

• Expanded annunciator data at the time of the

fault.

• Fault message and code.

• Hours of operation at the time of the fault.

• Sequence status at the time of the fault.

• Sequence time at the time of the fault.

— Diagnostic information:

• Device type.

• Flame amplifier type.

• Flame failure response time.

• Manufacturing code.

• On/Off status of all line voltage digital inputs.

• Software revision and version of RM7888A via

S7800 Keyboard Display Module.

• Status of configuration jumpers.

SPECIFICATIONS

Electrical Ratings (see Table 1):

Voltage and Frequency: 120 Vac (+10/-15%), 50/60 Hz

(±10%).

Keyboard Display Module: 13.0 Vdc peak full wave recti-

fied (+20/-15%).

Power Dissipation:

RM7888A: 10W maximum.

Display Module: 3W maximum.

Maximum Total Connected Load: 2000 VA.

Fusing: Total Connected Load: 20A maximum, type FRN or

equivalent.

Environmental Ratings:

Ambient Temperature:

Operating: -40° F to +140° F [-40° C to +60° C].

Storage: -40° F to + 150° F [-40° C to +66° C].

Humidity: 85% relative humidity continuous, noncon-

densing.

Vibration: 0.5G environment.

SIL 3 Capable:

SIL 3 Capable in a properly designed Safety Instrumented

System using Dynamic self check or amplicheck ampli-

fiers with the appropriate flame detector. See form

number 65-0312 for Certificate Agreement.

Dimensions: See Fig. 1

Weight:

RM7888A: 1 pound, 10 ounces [737 grams], unpacked.

Keyboard Display Module: 4 ounces [113 grams],

unpacked.

Approvals:

Underwriters Laboratories Inc. Listed: File No. MP268,

Vol. 30. UL 37260730-2-5 / CSA C22.2 No. 60730-

2-5.

Factory Mutual Approved: Report No. 1V9A0.AF.

Swiss Re (formerly Industrial Risk Insurers): Acceptable.

Federal Communications Commission: Part 15, Class

B, Emissions.

Exida: IEC 61508:2010 Parts 1-7, SIL 3 capable.

EAC Russia

RM7888A 7800 SERIES RELAY MODULE

332-00214—01

Fig. 1. Mounting dimensions of the RM7888A Relay Module and Q7800A Subbase in in. [mm].

NOTE: The RM7888 is a component of a larger overall

combustion safety system for industrial-burner

applications. Due to the custom design nature

inherent in industrial-burner control systems, the

system designer/ integrator has responsibility for

the overall combustion system safety and system

approval. Separate appliance or site approval may

also be required. The RM7888 serves as a system

component that provides control and flame

safety monitoring for an individual burner.

Mounting:

Q7800A1005 for panel mount or Q7800B1003 or B1011

for wall or burner mount.

Accessories:

Required for Operation:

Plug-in Flame Signal Amplifier (see Table 4).

This document provides installation and static checkout

instructions. Other applicable publications are:

M15518B

BURNER CONTROL

POWER

PILOT

FLAME

MAIN

ALARM

RESET

(127)

5 (127)

REMOVE ONLY FOR TERMINAL TEST ACCESS.

5-1/4 (133)

6-3/32 (155)

MODULE WITH SUBBASE

Part numbers Accessories

S7810M1003 Modbus Module (optional)

S7810A1009 DATA CONTROLBUS MODULE™

(optional)

123514A Flame Simulators Rectifying

203659 Flame Simulators Ultraviolet

S7800A1001 Keyboard Display Module

S7820A1007 Remote Reset Module

203765,

205321B,

204718B

Remote Display Mounting Brackets

221818A Extension Cable Assembly 60 inch

221818C Extension Cable Assembly 120 inch

A7800A1010 Tester

Form

Number Description

63-2278 Q7700A Network Interface Unit Product Data

65-0084 Q7800A,B 22-Terminal Wiring Subbase Product

Data

65-0090 S7800A Keyboard Display Module Product Data.

65-0091 S7810A Data ControlBus Module™ Product Data

65-0095 S7820 Remote Reset Module Product Data

65-0097 221729C Dust Cover Packing Sheet

65-0101 S7830 Expanded Annunciator Product Data

65-0109 R7824, R7847, R7848, R7849, R7851, R7861,

R7886 Flame Amplifiers for the 7800 SERIES

Product Data

65-0131 221818A Extension Cable Assembly Product Data

65-0229 7800 SERIES RELAY MODULES Checkout and

Test

RM7888A 7800 SERIES RELAY MODULE

32-00214—01 4

1The RM7888 must have an earth ground providing a connection between the subbase and the control panel or the

burner. The earth ground wire must be capable of conducting the current to blow the 15A fast blow fuse (or breaker) in

event of an internal short circuit. The RM7888 needs a low impedance ground connection to the equipment frame

which, in turn, needs a low impedance connection to earth ground. For a ground path to be low impedance at RF fre-

quencies, the connection must be made with minimum length conductors having maximum surface areas. Wide straps

or brackets are preferred rather than leadwires. Be careful to make sure that mechanically tightened joints along the

ground path, such as pipe or conduit threads or surfaces held together with fasteners, are free of nonconductive coat-

ings and are protected against mating surface corrosion.

22000 VA maximum connected load to RM7888A Assembly.

3See Table 2 and 3 for load combinations.

IMPORTANT

A Flame Detection System that must be ordered separately is required for operation. To select your Plugin Flame

Signal Amplifier and applicable Flame Detector, see Table 4.

Table 2. Combinations for Terminals 8, 9, and 10.

aJumper Terminals 8 to 9 for direct spark ignition.

Table 1. Terminal Ratings.

Terminal Number Description Ratings

GFlame Sensor Ground160 to 220 Vac, current limited.

Earth G Earth Ground1—

L2(N) Line Voltage Common —

3 Alarm 120 Vac, 1A pilot duty.

4 Line Voltage Supply (L1) 120 Vac (+10/-15%), 50/60 Hz (±10%)2

5 Air Valve 120 Vac, 9.8A FL, 58.8A LR (inrush).

6 Special Function 1 120 Vac, 1 mA.

7 Limits Complete 120 Vac, 9A.

8 Pilot Valve 3

9Main Fuel Valve

10 Ignition 3

F(11) Flame Sensor 60 to 220 Vac, current limited.

12(B) Firing Rate High Fire 120 Vac, 75 VA Pilot Duty.

13(R) Firing Rate Common 120 Vac, 75 VA Pilot Duty.

14(W) Firing Rate Low Fire 120 Vac, 75 VA Pilot Duty.

15 Firing Rate Modulate 120 Vac, 75 VA Pilot Duty.

16 Unused —

17 Special Function 2 120 Vac, 1 mA.

18 @Low Fire Input 120 Vac, 1 mA.

19 Special Function 3 120 Vac, 1 mA.

20 Special Function 4 120 Vac, 1 mA.

21 Flame Proven 120 Vac, 2A pilot duty.

22 Shutter 120 Vac, 0.5A.

Pilot Fuel 8 Main 9 Ignition 10

CFNo Load

BFNo Load

FFA

No Load F A

DFaA

DDA

No Load DaA

RM7888A 7800 SERIES RELAY MODULE

532-00214—01

Table 3. Composition of Each Combination.

ABCDF

4.5A ignition 50 VA Pilot Duty plus

4.5A ignition

180 VA Ignition plus

Motor Valves with:

660 VA inrush,

360 VA open,

250 VA hold.

2A Pilot Duty 65 VA Pilot Duty plus

motor valves with:

3850 VA inrush,

700 VA open,

250 VA hold.

Table 4. Flame Detection Systems (FIGS. 2–8).

Plug-In Flame Signal Amplifiers Applicable Flame Detectors

Type Color

Self-

Checking Model

Flame

Failure

Response

Time (sec)aFuel Type Models

Rectification Green No R7847Ae0.8 or 3 Gas Rectifying

Flame Rod

Holdersh

C7004,

C7007,

C7011

Complete

Assemblies:

C7008,

C7009, Q179

No R7847Ae3 Gas, oil, coal Ultraviolet

(Purple

Peeper)

C7012A,C

Dynamic

Amplicheck®R7847Bc,e 0.8 or 3 Gas Rectifying

Flame Rod

Holdersh

C7004,

C7007,

C7011,

Complete

Assemblies:

C7008,

C7009, Q179

Dynamic

Amplicheck R7847Bc,e 3 Gas, oil, coal Ultraviolet

(Purple

Peeper)

C7012A, C

Dynamic

Self-check R7847Cg3 Gas, oil, coal Ultraviolet

(Purple

Peeper)

C7012E, F

Infrared Red/White No R7852A 3 Gas, oil, coal Infrared C7915

Dynamic

Amplicheck

R7852B 3 Gas, oil, coal Infrared C7915

Ultraviolet Purple No R7849A 0.8 or 3 Gas, oil Ultraviolet

(Minipeeper)

C7027,

C7035,

C7044d

Dynamic

Amplicheck R7849Bd0.8 or 3 Gas, oil Ultraviolet

(Minipeeper)

C7027,

C7035,

C7044d

Dynamic

Self-Check R7861Ab0.8 or 3 Gas, oil, coal Ultraviolet C7061

Blue Dynamic

Self-Check

R7886 3 Gas, oil, coal Ultraviolet

(Adjustable

sensitivity)

C7076

Optical White Dynamic

Amplicheck

R7851B 0.8 or 3 Gas, oil, coal Optical (UV,

Visible Light)

C7927,

C7962

Dynamic

Self-Check R7851Cb3 Gas, oil, coal Optical (UV

only)

C7961

RM7888A 7800 SERIES RELAY MODULE

32-00214—01 6

a Flame Failure Response Time (FFRT) depends on selection of amplifier.

b Circuitry tests all electronic components in flame detection system (amplifier and detector) 12 times a minute during

burner operation and shuts down burner if detection system fails.

c Circuitry tests flame signal amplifier 12 times a minute during burner operation and shuts down burner if amplifier fails.

d Use C7027, C7035 and C7044 Flame Detectors only on burners that cycle on-off at least once every twenty-four hours.

Use C7061A Ultraviolet Detector with R7861A Amplifier or C7076A Flame Detector with R7886A Amplifier as ultraviolet

flame detection system for appliances with burners that remain on continuously for twenty-four hours or longer.

e R7847A,B Amplifiers with 0.8 second FFRT should NOT be used with C7012A,C Solid State Ultraviolet Detectors.

g R7847C Series 4 or greater, check flame detector system when flame reaches 1.5 Vdc or at 4.5 seconds, whichever

occurs first.

NOTE: R7847C Series 4 or greater, pulse the shutter when signal of 1.5 Vdc is sensed. Display readings of 0.7 to 2.4 Vdc

are common.

h Order flame rod separately; see flame detector Instructions for holder.

Fig. 2. Rectification detectors.

Fig. 3. Rectification detectors.

THREADED

MOUNTING

HOLES (2)

(10-32 UNF)

1 (25)

FLAME ROD

TARGET

CERAMIC

INSULATORS

IGNITION

ELECTRODE

(Q179C ONLY)

BRACKET

M1983B

3-1/8

(79)

1-21/32

(42)

1-13/32

(36)

3/8 (10)

1/2 (13)

1-1/16

(27)

25/32

(20)

25/32

(20)

2-25/32

(62)

3/32 (2) 11/16

(18)

17/32

(14)

MOUNTING FLANGE

1/2- 14 NPSM

LEADWIRES FACEPLATE

3/4-14 NPT

M1962D

3-3/4

(95)

7-7/32

(183)

5-1/8 (130)

3-7/16

(87)

5-1/4 (133)

C7012A,C,E,F, C7061

RM7888A 7800 SERIES RELAY MODULE

732-00214—01

Fig. 4. Infrared detector.

Fig. 5. Ultraviolet detectors (minipeepers).

Fig. 6. Ultraviolet detectors (minipeepers).

APERTURE

BUSHING WITH

MAGNIFYING LENS

COLLAR, 3/4-14 NPSM

INTERNAL THREADS

3/4-14

NPSM 3/4-14 NPSM

INTERNAL

THREADS

HEAT BLOCKCELL MOUNT

M1982C

2-3/4

(70)

1-1/4

(32)

1-5/8 (41)

1-1/16 (27)

1-1/4

(32)

C7915

COLLAR WITH 1/2-14 NPSM

INTERNAL THREADS

4 (102) 8 FOOT (2.44 METER)

LEADWIRES (2)

M1943G

C7027A1064 HAS 24 FOOT (7.32 METER) LEADWIRES. C7027A1114 HAS

44 IN. (1.118 M) LEADWIRES WITH 22 IN. (558 MM) FLEXIBLE CONDUIT.

3-1/2 (89)

1-1/16

(27)

MODELS AVAILABLE WITH SPUD CONNECTOR (1/2-14 NPSM INTERNAL

THREADS) INSTEAD OF CLAMP TYPE CONNECTOR.

1/2-14 NPSM

INTERNAL THREADS

2 (51)

COLLAR WITH

1 - 11-1/2 NPSM

INTERNAL

THREADS 1

1DIN APPROVED C7035A1064 HAS 1-11 BSP.P1 INTERNAL MOUNTING THREADS.

DIN APPROVED C7035A1064 HAS 1/2-14 BSP-F INTERNAL MOUNTING THREADS.

C7035A1056 HAS 12 FOOT (3.66 METER) LEADWIRES.

INSERTION DEPTH

6 FOOT

[1.83 METER]

LEADWIRES (2) 3

M1945E

2-5/8 (67)

1-1/2

(38)

31/32

(25)

4-1/8 (105)

1-3/16

(30)

RM7888A 7800 SERIES RELAY MODULE

32-00214—01 8

Fig. 7. Ultraviolet detectors (minipeepers).

Fig. 8. Ultraviolet detectors (minipeepers).

6 FOOT

[1.83 METER]

LEAD

WIRES (2)

3-5/8 (92)

1/2

(13)

1-27/64

(36)

3/8

(10)

7/8

(22)

9/16

(14)

M1944D

MOUNTING

BRACKET

(102)

4 (102)

3/8 INCH NPT

1 INCH NPT

7/8 (22) OPENING

FOR 1/2-INCH CONDUIT

ALLOW 9 INCHES (228 MILLIMETERS)

CLEARANCE TO SWING OUT THE DETECTOR

FOR LENS CLEANING OR SERVICING.

M5083C

1-1/16 (27)

2-1/4

(57)

2-1/4

(57)

4-27/32 (123)

1-13/32 (188)

10-9/32 (261)

2-5/16

(58)

29/32 (23)

3/4 (19)

1-19/32

(41)

2-11/16

(68)

7-5/8 (194)

C7076A

RM7888A 7800 SERIES RELAY MODULE

932-00214—01

Table 5. Sequence Timing for Operation.

* STANDBY and RUN can be an infinite time period.

** PURGE will be determined by the system master controller.

*** RM7888A1001 and A1019 are 4 seconds; RM7888A1027 is 10 seconds.

PRINCIPAL TECHNICAL

FEATURES

The RM7888A provides customary flame safeguard

functions while providing significant advancements in the

areas of safety, annunciation and system diagnostics.

Safety Shutdown (Lockout) Occurs

if:

1. INITIATE Period

a. Configuration jumper was changed (after 200

hours).

b. AC line power errors, see Operation section.

c. Four minute INITIATE period is exceeded.

2. STANDBY Period

a. Flame signal is present after 240 seconds.

b. Pilot valve/1st stage main valve terminal is ener-

gized.

c. Main valve terminal is energized.

d. Internal system fault.

e. Flame detected during the last two seconds.

f. Limits Complete is not energized after 120 sec-

onds.

g. Hold @Low Fire Switch is not energized after

eight minutes of hold.

h. Flame Proven terminal energized.

i. Ignition terminal energized.

j. Configuration jumpers select is illegal (during

last two seconds).

3. PILOT FLAME ESTABLISHING Period (PFEP) (Pilot

Configuration)

a. Pilot/1st stage main valve terminal is not ener-

gized.

b. No flame is present at end of PFEP.

c. Internal system fault.

d. Main valve terminal is energized.

e. Limits Complete is not energized.

f. @Low Fire is not energized.

g. Ignition terminal is not energized for the first ten

seconds of PFEP.

h. Ignition terminal is energized after the first ten

seconds of PFEP.

i. Flame Proven terminal is energized for the first

ten seconds of PFEP.

j. Flame Proven terminal is not energized at the

end of PFEP.

k. Special Function 2 is not energized after eight

minutes (Pilot Configuration).

4. MAIN FLAME ESTABLISHING Period.

a. Pilot is not energized.

b. Pilot/1st stage main valve terminal is not ener-

gized.

c. Main valve terminal is not energized.

d. No flame present.

e. Internal system fault.

f. @Low Fire switch is not energized.

g. Ignition terminal is energized.

h. Flame Proven is not energized.

i. Limits Complete is not energized.

j. Special Function 2 is not energized.

k. Special Function 3 is not energized.

5. RUN Period

a. No flame present.

b. Flame Proven is not energized.

c. Internal system fault.

d. Ignition terminal is energized.

e. Pilot terminal is energized (Pilot configuration).

f. Pilot terminal/main valve first stage is not ener-

gized (DSI configuration).

g. Limits Complete is not energized.

h. Main valve is not energized.

6. Anytime the configuration jumpers are changed

while the RM7888A is powered.

7. PILOT RELIGHT

a. Limits Complete is de-energized.

b. Special Function 2 is not energized.

c. Special Function 3 is not energized.

d. Ignition, pilot, or main is not energized.

e. Low Fire is not energized.

f. Flame failure.

g. Ignition terminal not energized.

h. Flame Proven is not energized.

8. WAIT FOR LOW OFF FOR 5 SECONDS

a. Limits Complete is not energized.

b. Special Function 2 is not energized.

c. Flame failure.

d. Ignition energized.

e. Main energized.

f. Flame Proven not energized.

g. Pilot not energized.

9. DRIVE TO LOW

RM7888A

Sequence Initiate Standby Purge

Pilot Flame

Establishing Period

(PFEP)

Main Flame

Establishing

Period (MFEP) Pilot Relight Run

Pilot: PV

Return

10 seconds * ** 10 seconds 10 seconds 5 sec to

infinity

Pilot: MV Lo

Fire

10 seconds * ** 10 seconds 15 seconds — *

DSI Normal 10 seconds * ** *** — — *

DSI High/Low

Stepfire

10 seconds * ** *** — — *

DSI On/Off

Stepfire

10 seconds * ** *** — — *

RM7888A 7800 SERIES RELAY MODULE

32-00214—01 10

a. Limits Complete is not energized.

b. Special Function 2 is not energized

c. Flame failure.

d. Ignition energized.

e. Main energized.

f. Flame Proven is not energized.

SAFTEY PROVISONS

Interal Hardware Status Monitoring

The RM7888A analyzes the integrity of the configuration

jumper and internal hardware. The POWER LED blinks

every four seconds to signify an internal hardware check.

Closed Loop Logic Test

The test verifies the integrity of all safety critical loads

(terminals 8, 9, 10 and 21). If the loads are not energized

properly, for example, the main valve terminal is powered

during purge, the RM7888A will lockout on a safety

shutdown. The RM7888A must react to input changes but

avoid the occurrence of nuisance shutdown events. Signal

conditioning is applied to line voltage inputs to verify

proper op-eration in the presence of normal electrical line

noise such as transient high voltage spikes or short

periods of line dropout. Signal conditioning is tolerant of

synchronous noise (line noise events that occur at the

same time during each line cycle).

Dynamic Flame Amplifier and

Shutter Check

Self-checking circuitry tests all electronic components in

the flame detection system and amplifier 12 times per

minute and shuts down the RM7888A if the detection

system fails.

Dynamic Amplifiercheck™

Dynamic Amplicheck™ circuitry tests the flame signal

amplifier during burner operation and shuts down

RM7888A if the flame amplifier fails.

Dynamic Input Check

All system input circuits are examined to make sure that

the RM7888A is capable of recognizing the true status of

external controls, limits and interlocks. If any input fails

this test, a safety shutdown occurs and the fault is

annunciated.

Dynamic Safety Relay Test

Checks the ability of the dynamic safety relay contacts to

open and close. Verifies that the safety critical loads

(terminals 8, 9, 10 and 21) can be de-energized, as

required, by the Dynamic Self-Check logic.

Dynamic Self-Check Safety Circuit

The microcomputer tests itself and related hardware, and

at the same time, the safety relay system tests the

microcomputer operation. If a microcomputer or safety

relay failure occurs and does not allow proper execution of

the self-check routine, safety shutdown occurs and all

safety critical loads will be de-energized.

Expanded Safe-Start Check

The conventional safe-start check, which prevents burner

start-up if flame is indicated at start-up, is expanded to

include a flame signal check during STANDBY, a safety

critical load check, a Limits Complete check, and an @Low

Fire check.

Off Cycle (Standby) Flame Signal

Check

The flame detection subsystem (flame detector and

amplifier) is monitored during STANDBY. If a flame

simulating condition or an actual flame exists for 40

seconds in STANDBY, a safety shutdown occurs and

startup is prevented. If the flame signal exists at any time

after 40 seconds during STANDBY, a safety shutdown

occurs and is annunciated.

• A shutter-check amplifier and self-checking detector

are energized continuously during STANDBY and the

last two seconds of STANDBY. If a flame exists, a safety

shutdown will occur.

• An Amplicheck™ Amplifier is energized continually

through STANDBY to detect any possibility of a

runaway detector or a flame. If either situation

happens, a safety shutdown will occur.

• A standard amplifier is energized continually through

STANDBY to detect any possibility of a runaway

detector or a flame. If either situation happens, a safety

shutdown will occur.

Tamper Resistant Timing Logic

Safety and logic timings are inaccessible and cannot be

altered or defeated.

Alarm Operation

This output will supply power to the system master and/ or

an external alarm indicator such as a bell or buzzer. The

alarm is turned on anytime a lockout has occurred and the

lockout condition has not been cleared. The alarm output

is also turned on when the reset button is pressed and

held for more than four seconds. The status of this output

is not monitored by the relay module.

First-Out Annuciation and Self-

Diagnostics

Sequence Status Lights (LEDs) provide positive visual

indication of the program sequence: POWER, PILOT,

FLAME, MAIN and ALARM. The green POWER LED blinks

every four seconds, signifying that the RM7888A

hardware is running correctly.

Optional Multi-function Keyboard Display Module shows

elapsed time during PILOT IGNITION and MAIN IGNITION.

As an additional troubleshooting aid, it provides RM7888A

SAFETY PROVISIONS sequence timing, diagnostic

information, and historical information when a safety

shutdown or hold or normal operation occurs.

First-out Annunciation reports the cause of a safety

shutdown or identifies the cause of a failure to start or

continue the burner control sequence with an English text

and numbered code via the Keyboard Display Module. It

monitors all field input circuits, including the flame signal

RM7888A 7800 SERIES RELAY MODULE

11 32-00214—01

amplifier and output circuits. The system distinguishes

modes of failure and detects and annunciates difficult-to-

find intermittent failures.

Self-diagnostics add to the First-out Annunciation by

allowing the RM7888A to distinguish between field

(external device) and internal (system related) problems.

Faults associated within the flame detection subsystem or

the RM7888A are isolated and reported by the optional

Keyboard Display Module. See Hold and Fault Message

Summary in the Checkout and Test, form 65-0229.

Interlock Requirements

The following interlock inputs are provided.

Limits Complete (Terminal 7)

This input provides an indication of the status of an

interlock string. If this input is energized, it is permissible

to operate through a burner sequence. The burner

sequence does not leave the Standby state if the Limits

Complete signal is de-energized. If this input becomes de-

energized after leaving the Standby state, one or more

interlocks are open and the burner sequence is either

recycled or a lockout occurs as defined for the particular

burner state.

@Low Fire (Terminal 18)

This input will provide an indication of the low firing rate

position. If this input is energized, the motor position is

assumed by the relay module to be at the Low Fire position;

otherwise, the motor position cannot be determined if this

input is de-energized.

This signal is readable in any burner operating state

without regard to the status of the special function signals

or the Limits Complete signal. The RM7888 does not

perform a test to assure that the Low Fire input signal

becomes energized when the High Fire motor control is

commanded. For example, the RM7888 will not detect a

Low Fire input that is jumpered or continuously energized

without regard to the actual motor position.

The High Fire position is not confirmed by a separate high

fire input at the RM7888. The system master control is

responsible for the High Fire proving and purging of the

combustion unit.

INSTALLATION

WARNING

FIRE OR EXPLOSION HAZARD CAN CAUSE

PROPERTY DAMAGE, SEVERE INJURY, OR

DEATH.

To prevent possible hazardous burner operation,

perform verification of safety requirements each

time a control is installed on a burner.

When Installing This Product...

1. Read these instructions carefully. Failure to follow

them could damage the product or cause a hazard-

ous condition.

2. Check the ratings given in the instructions and

marked on the product to make sure the product is

suitable for your application.

3. Installer must be a trained, experienced, flame safe-

guard service technician.

4. After installation is complete, check out the product

operation as provided in these instructions.

CAUTION

To prevent electrical shock and equipment

damage, disconnect the power supply before

beginning installation. More than one power

supply disconnect may be involved.

1. To prevent electrical shock and equipment damage,

disconnect the power supply before beginning

installation. More than one power supply disconnect

may be involved.

2. Wiring connections for the RM7888A are unique;

therefore, refer to Fig. 11 or the correct specifica-

tions for proper subbase wiring.

3. Wiring must comply with all applicable codes, ordi-

nances and regulations.

4. Wiring, where required, must comply with NEC Class

1 (Line Voltage) wiring.

5. Loads connected to the RM7888A must not exceed

those listed on the RM7888A label or the specifica-

tions (see Table 1).

6. Limits and interlocks must be rated to carry and

break current simultaneously to the ignition trans-

former, pilot valve, and main fuel valve(s).

7. All external timers must be listed or component rec-

ognized by authorities who have jurisdiction for the

specific application.

RM7888A 7800 SERIES RELAY MODULE

32-00214—01 12

IMPORTANT:

1. For on-off gas-fired systems, some authorities

who have jurisdiction prohibit the wiring of any

limit or operating contacts in series between the

flame safeguard control and the main fuel valve(s).

2. Two detectors can be connected in parallel, with

the exception of the Solid State detectors (C7915,

C7927, C7962 and C7961).

3. This equipment generates, uses and can radiate

radio frequency energy, and if not installed and

used in accordance with the instructions, may

cause interference to radio communications. It

has been tested and found to comply with the lim-

its for a Class A computing device of part 15 of

FCC rules, which are designed to provide reason-

able protection against such interference when

operated in a commercial environment. Operation

of this equipment in a residential area may cause

interference, in which case the users, at their own

expense, may be required to take whatever mea-

sures are required to correct this interference.

4. This digital apparatus does not exceed the Class A

limits for radio noise of digital apparatus set out in

the Radio Interference Regulations of the Cana-

dian Department of Communications.

5. RM7888A cannot be connected in parallel without

isolation circuits to isolate input and output cir-

cuits.

Humidity

Install the RM7888A where the relative humidity never

reaches the saturation point. The RM7888A is designed to

operate in a continuous, noncondensing moisture

environment with a maximum 85 percent relative

humidity. Condensing moisture can cause a shutdown.

Vibration

Do not install RM7888A where it could be subjected to

vibration in excess of 0.5G continuous maximum

vibration.

Weather

The RM7888A is not designed to be weather tight. If

installed outdoors, the RM7888A must be protected by an

approved weather-tight enclosure.

Relay Module and Subbase

Compatiblity

NOTE: There are several different subbase models that

can be purchased. It is important to note which

subbase is compatible with the relay module

when purchasing new, repair or replacement

parts.

Series 1000 Relay Modules

All relay product codes that start with a 1 (example:

RM7840G1014/U) can be used with existing subbase

Q7800A1003/U and Q7800A1005/U.

Series 2000 Relay Modules

All relay product codes that start with a 2 (example:

RM7840G2014/U) must be used with subbase

Q7800A2003/U and Q7800A2005/U.

Subbase Compatibility

Any Relay Module in the 1000 Series with a Software

Revision level number starting with a "5" or greater will be

compatible with all subbase models both installed and

newly purchased. This includes (Q7800A1005/U,

Q7800B1003/U), and the 2000 Series subbases

(Q7800A2005/U, Q7800B2003/U).

See Fig. 1 for Software Revision Level number location on

the label (located on the rear of the relay module).

Any relay module in the new 2000 series will only be able

to be installed on subbase Q7800A2005/U,

Q7800B2003/U and will not be backward compatible with

any Q7800A1003/U and Q7800A1005/U subbases

already installed in the field.

Fig. 9. Software revision location.

IMPORTANT

Make sure to check the relay model number and

the software revision level on the relay.

• If you attempt to place a 2000 series relay on a

non-compatible 1000 series subbase, you will

receive an error code of 101. This indicates that

you must a) change out the subbase to a

Q7800A2003/U or Q7800A2005/U or b) choose a

compatible 1000 series relay module.

Mounting Wiring Subbase

NOTE: For installation dimensions, see Fig. 1.

1. Mount the subbase in any position except horizon-

tally with the bifurcated contacts pointing down. The

standard vertical position is recommended. Any

other position decreases the maximum ambient

temperature rating.

2. Select a location on a wall, burner or in an electrical

panel. The Q7800 can be mounted directly in the

control cabinet. Be sure to allow adequate clearance

for servicing, installation, access and removal of

RM7888A, dust cover, flame amplifier, flame ampli-

fier signal voltage probes, electrical signal voltage

probes and electrical field connections.

3. For surface mounting, use the back of the subbase

as a template to mark the four screw locations. Drill

the pilot holes.

RM7888A 7800 SERIES RELAY MODULE

13 32-00214—01

4. Mount the subbase securely using four No. 6 screws.

NOTE: You might receive an error code 101 (via KDM) if

one of the following conditions exist:

a. The screws securing the relay to the subbase are

not tight enough, re-tighten to insure there is no

gap between the relay and the subbase.

b. If you attempt to place a 2000 series relay on a

non-compatible 1000 series subbase, this indi-

cates that you must:

• Change out the subbase to a Q7800A2003/U

or Q7800A2005/U

• Choose a compatible 1000 series relay

modulebase to a Q7800A2003/U or

Q7800A2005/U

WIRING

a. For the internal block diagram of the RM7888A,

see Fig. 10.

b. For proper subbase wiring, refer to Fig. 11.

c. For proper remote wiring of the Keyboard Display

Module; refer to the Specifications for the Key-

board Display Module (65-0090), or Extension

Cable Assembly (65-0131).

2. Disconnect the power supply from the main discon-

nect before beginning installation to prevent electri-

cal shock and equipment damage. More than one

disconnect may be involved.

3. All wiring must comply with all appropriate electrical

codes, ordinances and regulations. Wiring, where

required, must comply with NEC Class 1 wiring.

Fig. 10. RM7888A internal block diagram.

CONFIGURATION

JUMPERS

MICROCOMPUTER

RESET

PUSHBUTTON

STATUS LEDs

SAFETY RELAY

CIRCUIT

POWER SUPPLY

OPTIONAL

KEYBOARD

DISPLAY MODULE

PLUG-IN

FLAME

AMPLIFIER

RELAY

DRIVE

CIRCUIT

CONTROL

POWER

TEST

JACK

REMOTE

RESET

DDL

COMMUNICATIONS

INDICATES FEEDBACK SENSING

OF RELAY CONTACT

AND LINE VOLT INPUTS

FIELD WIRING

INTERNAL WIRING

IGNITION

AIRVALVE

MAIN VALVE

RELAY

STATUS

FEEDBACK

AND LINE

VOLTAGE

INPUTS

1K1 5K1

120 Vac

FLAME SIGNAL

TEST

PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

120 VAC INPUT FROM SYSTEM MASTER CONTROLLER REFER TO

TABLE 1 AND FIGURE 8.

RS485

L1 (HOT) L2

6K1

4K1

2K2

FLAME

PROVEN

7K1

M9496D

LIMITS COMPLETE

ALARM

PILOT

SPECIAL FUNCTION 1

18 LOW FIRE

SWITCH

SPECIAL

FUNCTION 2

SPECIAL

FUNCTION 3

SPECIAL

FUNCTION 4

8K1

HIGH FIRE 12

COMMON 13

MODULATE

LOW FIRE 14

9K1

8K2

9K2

2K2

3K1

RM7888A 7800 SERIES RELAY MODULE

32-00214—01 14

Fig. 11. RM7888A wiring diagram.

4. Recommended wire size and type:

a. Use 14, 16, or 18 AWG copper conductor

(TTW60C or THW75C or THHN90C) 600 volt

insulation wire for all line voltage terminals. For

high temperature installations, use wire selected

for a temperature rating above the maximum

operating temperature. All leadwires must be

moisture resistant.

b. Keyboard Display Module—For communications

purposes, use an unshielded 3-wire twisted

cable if the leadwire run and noise conditions

permit; however, some installations may need up

to five wires; three for communications and two

for remote reset (either in a single cable or sepa-

rate cables for communications or remote reset)

or use Belden 8771 shielded cable or equivalent.

The Keyboard Display Module, DATA CONTROL-

BUS MODULE™ (for remote mounting or com-

munications) or Modbus Module must be wired

in a daisy-chain configuration, 1(a)-1(a), 2(b)-

2(b), 3(c)- 3(c)). The order of interconnection of

all the devices is not important. Be aware that

modules on the closest and farthest end of the

daisy chain configuration require a 120-ohm

(1/4 watt minimum) resistor termination across

terminals 1 and 2 of the electrical connectors for

connections over 100 feet [30 meters].

c. DATA CONTROLBUS or MODBUS MODULE™—

For communications purposes, use an

unshielded 3-wire twisted cable if the leadwire

run and noise conditions permit; however, some

installations may need up to five wires; three for

communications and two for remote rest (either

in a single cable or separate cables for communi-

cations or remote reset) or use Belden 8771

shielded cable or equivalent. The Keyboard Dis-

play Module, DATA CONTROLBUS MODULE™

(for remote mounting or communications) or

Modbus Module must be wired in a daisy-chain

configuration, 1(a)-1(a), 2(b)-2(b),3(c)-3(c)). The

order of interconnection of all the devices is not

important. Be aware that modules on the closest

and farthest end of the daisy chain configuration

require a 120-ohm (1/4 watt minimum) resistor

termination across terminals 1 and 2 of the elec-

trical connectors for connections over 100 feet

[30 meters].

M9495A

(L1)

MASTER

SWITCH

LIMITS

SPECIAL

FUNCTION 1

SPECIAL

FUNCTION 2

SPECIAL

FUNCTION 3

SPECIAL

FUNCTION 4

FLAME

INDICATION

MAIN FUEL

VALVE(S)

120V ALARM

PILOT

FLAME

DETECTOR

120V POWER SUPPLY. PROVIDE DISCONNECT MEANS

AND OVERLOAD PROTECTION AS REQUIRED.

(HOT)

Q7800 SUBBASE HIGH

FIRE

COMMON

LOW

FIRE

MODULATE

SERIES 90

FIRING

RATE

MOTOR

SERIES 90

CONTROLLER

LOW FIRE

SWITCH

IGNITION

AIR VALVE

EXTERNAL

CONTROLLER

FOR DIRECT SPARK

IGNITION (OIL OR GAS)

IGNITION

2ND STAGE

FUEL VALVE

1ST STAGE

FUEL VALVE 8

RM7888A 7800 SERIES RELAY MODULE

15 32-00214—01

d. Remote Reset—Use 22 AWG or greater twisted

pair wire, insulated for low voltage.

5. Recommended grounding practices:

a. Use earth ground to provide a connection

between the subbase and the control panel or

the equipment. The earth ground wire must be

capable of conducting the current to blow the

15A fast blow fuse (or breaker) in the event of an

internal short circuit. The RM7888A needs a low

impedance ground connection to the equipment

frame which, in turn, needs a low impedance

connection to earth ground. For a ground path to

be low impedance at RF frequencies, the connec-

tion must be made with minimum length con-

ductors that have a maximum surface area. Wide

straps or brackets are preferred rather than lead-

wires. Make sure that mechanically tightened

joints along the ground path, such as pipe or

conduit threads or surfaces held together with

fasteners, are free of nonconductive coatings

and are protected against mating surface corro-

sion.

b. Keyboard Display Module, DATA CONTROLBUS

MODULE™ or Modbus Module—The shield, if

used, should be connected to the signal ground

terminal 3(c) provided as part of the 7800

SERIES device ControlBus connection. The

shield should be connected at both ends to

ground.

c. RM7888A—Each RM7888A will have an earth

ground terminal that must be grounded to the

metal control panel with wire as short as practi-

cal. Each ground wire must be capable of carry-

ing a fault current equal to the rating of the

protective fuse 15A fast blow. A 14 AWG copper

conductor is adequate, but wide straps or brack-

ets are preferred to leadwires.

6. Recommended wire routing:

a. Flame detector leadwires:

(1) Do not run high voltage ignition transformer

wires in the same conduit with flame detec-

tion wiring.

(2) Do not route scanner wires in a conduit with

line voltage circuits.

(3) Enclose scanner wires without armor cable in

metal cable or conduit.

(4) Follow directions given in flame detector

instructions.

b. DATA CONTROLBUS MODULE™ or Modbus

Module:

(1) Do not run high voltage ignition transformer

wires in the same conduit or in close proxim-

ity to the MODULE wiring.

(2) Do not route MODULE wires in conduit with

line voltage circuits.

c. Keyboard Display Module:

(1) Because the VFD is powered from a low volt-

age, energy limited source, mount it outside a

control panel, without using special wiring

procedures, if it is protected from mechanical

damage.

d. Remote Reset:

(1) Do not run high voltage ignition transformer

wires in the same conduit with the Remote

Reset wiring.

(2) Do not route Remote Reset wires in the same

conduit with line voltage circuits.

7. Maximum wire lengths:

a. For the flame detector leadwires, the maximum

flame sensor leadwire length is limited by the

flame signal strength.

b. For the Remote Reset leadwires, the maximum

length of wire is 1000 feet to a Remote Reset

pushbutton.

c. For the DATA CONTROLBUS or MODBUS MOD-

ULE™, the maximum cable length depends on

the number of system modules connected, the

noise conditions and the cable used. The maxi-

mum length of all interconnecting wire is 1000

feet [305 meters].

8. Make sure loads do not exceed the terminal ratings.

Refer to the label on the RM7888A or to the ratings

in the specifications; see Table 1.

9. Check the power supply circuit. The voltage and fre-

quency tolerance must match those of the

RM7888A. A separate power supply circuit may be

required for the RM7888A with the required discon-

nect means and overload protection added.

10. Check all wiring circuits and complete the Static

Checkout before installing the RM7888A on the sub-

base: see Table 10.

11. Install all electrical connectors.

12. Restore power to the panel.

ASSEMBLY

Mounting the RM7888A

NOTE: For installation dimensions, see Figs. 1

Relay Module Mounting

(Figs. 12 and 13)

1. Mount RM7888A vertically, see Figs. 12 or 13, or

mount horizontally with the knife blade terminals

pointing downward. When mounted on the Q7800A,

the RM7888A must be in an electrical enclosure.

2. Select the location in the electrical enclosure. Be

sure to allow adequate clearance for servicing,

installation and removal of the RM7888A, Keyboard

Display Module, flame amplifier, flame amplifier sig-

nal voltage probes, electrical signal voltage probes

and electrical connections.

a. Allow an additional two inches below the

RM7888A for the flame amplifier mounting.

b. Allow an optional three-inch minimum to both

sides of the RM7888A for electrical signal volt-

age probes.

3. Make sure no subbase wiring is projecting beyond

the terminal blocks. Tuck in wiring against the back

of the subbase so it does not interfere with the knife

blade terminals or bifurcated contacts.

IMPORTANT:

The RM7888A must be installed with a plug-in

motion rather than a hinge action.

RM7888A 7800 SERIES RELAY MODULE

32-00214—01 16

Fig. 12. Electrical panel installation.

Fig. 13. Wall or burner installation.

4. Mount the RM7888A by aligning the four L-shaped

corner guides and knife blade terminals with the

bifurcated contacts on the wiring subbase and

securely tightening the two screws without deform-

ing the plastic.

Mounting the Keyboard Display

Module (Fig. 14)

1. Align the two interlocking ears of the Keyboard Dis-

play Module with the two mating slots on the

RM7888A.

2. Insert the two interlocking ears into the two mating

slots and, with a hinge action, push on the lower cor-

ners of the Keyboard Display Module to secure it to

the RM7888A.

3. Make sure the Keyboard Display Module is firmly in

place.

Fig. 14. Keyboard Display Module mounting.

Mounting the Data Controlbus

Module™, Modbus Module or the

Extension Cable Assembly (Figs. 15

and 16)

1. Align the two interlocking ears with the two mating

slots on the RM7888A.

2. Insert the two interlocking ears into the two mating

slots and push on the lower corners of the DATA

CONTROLBUS MODULE™, Modbus module or

Extension Cable Assembly to secure it to the

RM7888A.

3. Make sure the modules are is firmly in place.

Fig. 15. DATA CONTROLBUS MODULE™ mounting.

RM7888A 7800 SERIES RELAY MODULE

17 32-00214—01

Fig. 16. Extension Cable Assembly mounting.

Remote Mounting the Keyboard

Display Module (Fig. 17)

1. The Keyboard Display Module can be mounted

either on the face of a panel door or other remote

locations.

NOTE: A DATA CONTROLBUS MODULE™ or an Exten-

sion Cable Assembly is required to connect

RM7888A to a remote Keyboard Display Module.

2. When mounting the Keyboard Display Module on

the face of the door panel, closely follow these

instructions:

a. Select the location on the door panel for flush

mounting. Pay attention to the insertion dimen-

sion of the two Keyboard Display Module screws,

two interlocking ears and the two plug-in con-

nectors to allow for sufficient clearance (1/4 in.

[6 mm] minimum) inward from the surface of the

door panel.

b. Mark the two screw locations, two interlocking

ear locations and the two plug-in connector

locations. Drill the pilot holes for the mounting

screws. Provide for two holes on the door panel

for the interlocking ears and two holes for the

plug-in connectors.

c. Mount the Keyboard Display Module on the door

using two no. 4 screws.

3. When mounting the Keyboard Display Module on a

wall or remote location, use part number 203765,

Remote Mounting Bracket.

a. Using the Remote Mounting Bracket as a tem-

plate, mark the four screw locations and drill the

pilot holes.

b. Mount the Remote Mounting Bracket using four

no. 6 screws.

c. Mount the Keyboard Display Module by aligning

the two interlocking ears with the two mating

slots on the Remote Mounting Bracket.

d. Insert the two interlocking ears into the two mat-

ing slots. Push on lower corners of the Keyboard

Display Module to secure it to the Remote

Mounting Bracket. e. Make sure the Keyboard

Display Module is firmly in place.

Installing the Plug-in Flame Signal

Amplifier

1. Disconnect the power supply before beginning the

installation to prevent electrical shock and equip-

ment damage. More than one disconnect may be

involved.

2. Align the amplifier circuit board edge connector with

the keyed receptacle on the RM7888A. Make sure

the amplifier nameplate faces away from the Relay

Module.

3. Push in the amplifier until the circuit board is fully

inserted into the receptacle and then push the

amplifier toward the RM7888A retaining clasp.

4. Make sure the amplifier is firmly in place.

5. Perform all required checkout tests.

Fig. 17. Remote mounting of Keyboard Display Module.

RM7888A 7800 SERIES RELAY MODULE

32-00214—01 18

Fig. 18. Flame signal amplifier mounting.

Installing the Flame Detector (Fig.

19)

NOTE: Table 4 lists the flame detection systems avail-

able for use with the RM7888A. Make sure the

correct combination of amplifier and flame detec-

tor(s) is used.

Proper flame detector installation is the basis of a safe

and reliable flame safeguard installation. Refer to the

instructions packed with the flame detector and the

equipment manufacturer instructions.

Keep the flame signal leadwires as short as possible from

the flame detector to the wiring subbase. Capacitance

increases with leadwire length, decreasing the signal

strength. The maximum permissible leadwire length

depends on the type of flame detector, leadwire and

conduit. The ultimate limiting factor in the flame signal is

the flame detector leadwire.

Fig. 19. Flame detector wiring.

BLUE

YELLOW

WHITE

BLACK

M1969C

BLUE

WHITE

BLUE

WHITE

INFRARED (C7915)

ULTRAVIOLET (C7027/C7035/C7044)

SOLID STATE SELF-CHECKING

ULTRAVIOLET (C7012E,F)

BLUE

YELLOW

BLACK

SOLID STATE

ULTRAVIOLET (C7012A,C)

F G

C7076A,D ULTRAVIOLET DETECTOR

522

SHUTTER

7800 SERIES

3a 3b

REMOTE

SENSOR

EARTH

GROUND

C7076A

C7076D

TERMINAL

BLOCK

L2 (COMMON)

L1 (HOT)

FLAME ROD

PHOTOCELL

1FLAME DETECTOR LEADS ARE COLOR CODED. THE BLUE LEAD MUST BE CONNECTED TO THE F TERMINAL AND THE WHITE

MUST BE CONNECTED TO THE G TERMINAL. THE UV SENSING TUBE IS POLARITY SENSITIVE. REVERSING THE LEADS EVEN

MOMENTARILY CAN DAMAGE OR DESTROY THE UV TUBE.

FLAME DETECTOR LEADS ARE COLOR CODED. THE BLUE LEAD MUST BE CONNECTED TO THE F TERMINAL AND THE YELLOW

MUST BE CONNECTED TO THE G TERMINAL. THE UV SENSING TUBE IS POLARITY SENSITIVE. REVERSING THE LEADS EVEN

MOMENTARILY CAN DAMAGE OR DESTROY THE UV TUBE.

RM7888A 7800 SERIES RELAY MODULE

19 32-00214—01

OPERATION

WARNING

The user of the RM7888A is responsible for

providing an effective purge that meets the

approval of the authority having jurisdiction for a

particular installation. Failure to provide an

effective purge can result in a fire or explosion

that can cause damage, serious injury or death.

Sequences of Operation

The RM7888A has five user selectable operating

sequences: Pilot—PV Return; Pilot—MV Lo Fire; Direct

Spark Ignition (DSI) Normal Operating Sequence; DSI

High/Low Stepfire Operating Sequence and DSI Off/On

Stepfire Operating Sequence. Each operating sequence

will be discussed in detail.

CAUTION

The user selects the appropriate control

sequence by clipping configuration jumpers.

Sequence selection must be done correctly.

Failure to select the sequence correctly can be

hazardous. Follow instructions in this

specification.

Selectable Site-Configurable

Jumpers

The RM7888A has five site-configurable jumper options

and three options that will result in a lockout, see Fig. 20

and Table 6. The site-configurable jumpers should be

clipped with side cutters and the resistor removed from

the Relay Module.

Fig. 20. Selectable site-configurable jumpers.

Table 6. Site-Configurable Jumper Options.

1 Each operating sequence is described individually in the Operation section of this specification. Read the appropriate

operating sequence section carefully before clipping jumpers. The sequence selection cannot be reversed.

Pilot Configuration Operating

Sequence

The Pilot Configuration Operating Sequence has two

distinct operating sequences that are entered from the

Standby/ Standby Purge states. The sequences are:

a. PV Return: allows the control to reestablish the

pilot and de-energize the main flame in response

to the system heating requirements.

b. MV Lo Fire: will not allow the pilot to be re-estab-

lished once RUN has been entered; the main

valve remains energized with Lo Fire being the

lowest firing rate allowed.

See Table 7 for the state names, the text that appears on

the S7800 Keyboard Display Module, and the purpose.

SELECTABLE CONFIGURATION JUMPERS

M7861A

Jumper

RM7888A ActionJ1 J2 J3

Intact Intact Intact Default, selects the Pilot Configuration Burner

Sequence, including the Pilot Relight Function.(PV

Return)1

Intact Clipped Clipped Selects DSI Normal Burner Sequence.1

Clipped Intact Clipped Selects DSI High/Low Stepfire Burner Sequence.1

Clipped Clipped Intact Selects DSI Off/On Stepfire Burner Sequence.1

Intact Intact Clipped Selects Pilot Configuration Burner Sequence, but

excludes the Pilot Relight Function.(MV Lo Fire)1.

Intact Clipped Intact Illegal; will result in a lockout.

Clipped Intact Intact Illegal; will result in a lockout.

Clipped Clipped Clipped Illegal; will result in a lockout.

RM7888A 7800 SERIES RELAY MODULE

32-00214—01 20

Table 7. Pilot Configuration Operation Sequence States.

Pilot Configuration

State Name

S7800 Keyboard

Display Module

Displayed Text Purpose of State

Initiate (See below) The Initiate state allows the relay module to complete initialization after a

power-up or whenever a problem that would prevent normal operation (such

as an ac line problem), the Initiate state is entered.

Initiate INITIATE mm:ss Displayed during timed portion of the Initiate state.

Initiate INITIATE HOLD: AC

(AC Freq/Noise)

Displayed during Initiate state if the ac frequency is low or noise is present.

Initiate INITIATE HOLD: AC

(AC Line Dropout)

Displayed during Initiate state if the ac line power was lost.

Initiate INITIATE HOLD: AC

(AC Frequency)

Displayed during Initiate state if the ac frequency is high.

Initiate INITIATE HOLD: AC

(Low Line Voltage)

Displayed during Initiate state if the ac line voltage is low.

Off STANDBY Remaining idle until valid input(s) are received. All safety loads are

commanded off.

— STANDBY HOLD: F/G

(Flame Detected)

Displayed when a flame is detected.

— STANDBY HOLD: T7

(Lockout ILK)

Displayed when a call for operation is active and the Limits Complete signal

is off.

PURGE HOLD: T18

(Low Fire Switch)

Displayed when a call for operation is active and the Low Fire Switch signal

is off.

Purge PURGE 01:00 Purge at high fire. All safety loads are commanded off. Display indicates

Purge type 1 = Purge.

Control Cool PURGE 02:00 Purge at the motor position commanded by the modulating control. All

safety loads are commanded off. Display indicates Purge type 2 = Control

Cool.

Low Combustion Air

Only

PURGE 03:00 Purge at low fire. All safety loads are commanded off. Display indicates

Purge type 3 = Low Combustion Air Only.

Pilot Ignition PILOT IGN mm:ss Establish a pilot flame. Display shows state and elapsed time. At end of Pilot

Ignition timed state, timer will stop and display will show final time while a

hold exists.

Main Train Fuel On MAIN IGN 00:00 Allow for main valve operators to be placed into the normal operating

condition. Display shows state with zero elapsed time while waiting for a

hold condition(s).

Burner Fuel Valve

Open (Pilot Timeout)

MAIN IGN 00:ss Establish a main flame and drop the pilot flame. Display will show MFEP

state elapsed time.

Release to

Modulation

RUN Allow normal operation to take place where a modulating control provides

the motor position signal.

— RUN When special function input terminal 20 is off, relay module will command a

Low Fire motor position.

@Low 10 Sec RUN When the Low Fire input becomes energized for a continuous time period of

10 seconds, the sequence will leave the Release to Modulation state and

proceed to the Pilot Relight state (PV Return sequence only).

Pilot Relight PVHOLD IGN 00:ss Re-establish the pilot flame and drop the main flame. Display indicates

elapsed time in this timed state (PV Return sequence only).

Low Off 5 Sec. PVHOLD IGN 01:00 Wait for the Low Fire input signal to become de-energized for a continuous

period of five seconds and then proceed to the Main Train Fuel On state

after driving back to the Low Fire position. Display indicates that sequence

is in Pilot Hold State type 1 = Waiting for Low Off 5 Sec.

Drive to Low PVHOLD IGN 02:00 Commands the low fire motor position and waits until the Low Fire input

becomes energized before proceeding to the Main Train Fuel On state.

Display indicates that sequence is in Pilot Hold State type 2 = Waiting for

Low Fire On.

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Honeywell 7800 series Operating instructions

Brand: Honeywell

Model: 7800 series

Type: Operating instructions

This manual is also suitable for

RM7888A

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Honeywell 7800 series Operating instructions

This manual is also suitable for

Honeywell 7800 series Operating instructions

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